Technical Sales Agents www.greenhouseeffect.co.uk structuran & decoran Crystallized Glass Ceramic Formed From 100% Recycled Float Glass Preface Designed with specifiers in mind, this brochure describes the character, potential applications and design best practice for a new, revolutionary sheet material, currently in application within the construction and interiors market. 1 Technical Data File Rev 11.09
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Technical Sales Agents www.greenhouseeffect.co.uk
structuran & decoran Crystallized Glass Ceramic
Formed From 100% Recycled Float Glass
Preface
Designed with specifiers in mind, this brochure describes the character, potential
applications and design best practice for a new, revolutionary sheet material,
currently in application within the construction and interiors market.
1
Technical Data File Rev 11.09
Contents
A New Material
Material Branding Description
Material Nature and Characteristics
Colours
Nature & Qualities
Trade Pricing Guide
Design and Specification Advice – best practice
Ventilated Rain Screen External Façades
Interior Applications:
Solid Surfaces (kitchens, bars, vanities, tables)
Kitchen Splash Backs
Shower Screens
Internal Linings
Lit Feature
Flooring
Barriers
“Glazing”
Technical Specifications, Testing and Approvals
Project Precedents
Façades, UK and World
Interiors, UK and World
Agent Contact Details
2
A New Material
Material Branding
Described fully as crystallized, annealed glassceramic, this pioneering material
should not be specified as glass per se but more as a unique stone-like material.
Just as you would expect and desire from a natural stone, this exquisite material
exhibits natural inconsistencies and flaws, is generally thick, with one finished
side (unless the calibrated underside is intended to be polished), and cutting and
edging is processed. Given that the material is not toughenable, like granite it
will break into shards and pellets during destruction testing.
Based in the UK, The Greenhouse Effect Ltd are the main technical sales
agents for German patent holders and producers Indupart Glaskeramik GmbH.
Sheets are held both in the UK and abroad in order to facilitate completion of
smaller scale decoran projects.
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glass ceramic, formed from 100% recycled float glass, is a
revolutionary and highly versatile material, with the combined characteristics of
glass and natural stone. Primarily aimed at external applications as a rain screen
façade cladding material, structuran® offers either the warm opacity of natural
stone, or refined, contemporary levels of translucency – and even transparency –
coupled with an unrivaled anti-stain quality and durability. Defined by its
outstanding strength characteristics and integrity, with a Fischer FZP-GZ
undercut anchor, structuran® has a more limited palette than decoran®. Offering
a thinner façade panel solution than stone, thus saving structure, structuran® is
available in larger panels. In earthquake zones, structuran® has a general
European approval for cladding at a height of 100m.
Galaxy Polished and back lit decoran reception desk
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glass ceramic is the luxury solution for interior and non anchored
applications, including internal linings, feature walls, kitchen and bar surfaces,
flooring and stairs, memorials, screens, vanity tops and sinks, and should be
specified as a stone slab material.
With a competitive edge over translucent stone rival Onyx, in terms of price,
sustainability and evenness of colour, glass ceramic has unrivalled anti-stain
qualities, as well as highly enviable environmental credentials, as no resins are
used in the bonding process. Instead, glass crystals are heated to a sintering
point and then control-cooled.
Material Nature and Characteristics
Specification and Environmental Advantages
This highly sought material is produced entirely from float glass (or bottle glass
as with some decoran®) manufacturers’ waste cullet and formed in 2780mm by
1260mm sheets in varying thicknesses of between 15-23mm, although generally
20-21mm and 21-23mm for structuran®. Consuming just a third of the energy
otherwise required for reprocessing at high temperature, the material is fired
using bio-gas energy sources, wherever possible. Once the material has been
sintered and formed into sheets, these are then control-cooled, such that the
tensile stresses within the glass are moved to the panel edge, providing
increased stability, and thus rendering the material in its nature more like granite.
The naturally textured “hammered” top surface which results, similar to the bush
hammering of stone surfaces, can then be polished down to create a more
luxurious reflective finish. Although the underside is generally left as a calibrated
flat surface, this too can be polished upon request if visible. Air bubbles
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contained within are another unique characteristic of the material, and are kept
below a 3mm diameter, predominantly away from the top surface. On cutting,
these can be left open, appearing on the rear side.
While safety glazing requirements relate in principle only to clear glass, break
safe characteristics can also be achieved in our materials, through either the
introduction of an additional film or mesh, or via the insertion of a honeycomb
background that can be light transmitting – suitable for ceilings and other
overhead locations where safety surety is paramount.
Panel Type Size (mm)
Standard Panels(3 from a full sheet)
20x 1200x900
Maximum Panels (hammered) 20x 1260x2780(20x 1200x2700 polished)
For the purposes of façade applications, a 21-23mm thickness provides the
requisite strength for façade panels of 2m x 1.1m size, up to a height of 100m, as
approved by the EU.
In tandem with the EU, the UK is currently carrying out new soft body impact
tests, which are expected to allow the use of 21+mm thicknesses for cladding
purposes. In addition to pull out anchor testing and continental soft body impact
data, we are now able to provide positive UK test data on absorption and flexural
strength, as performed by Sandberg consultants.
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Colours
Translucent colours Jade and Galaxy, produced from float glass and low iron
glass respectively, form our standard colour range. Highly popular, these colours
are keenly specified due to their glass-like qualities and are, therefore, generally
held in stock for decoran® and structuran® use. On request, however, a full
range of bespoke opaque colours is also available. Unless UV damage requires
otherwise, the pigments thus added are organic. Using smaller cullet sizes with
greater crystallization, the hammered finish, opaque colours which result are
more akin to natural stone.
Two Standard Colours - Two Finishes
Jade Polished Galaxy Hammered
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Colours – Standard and Customised
Endless colour choices and finishes are offered bespoke with minimum orders
Jade Galaxy White
Orient Red Azul Blue Pacific Grey
Fossil Siena Brown Pearl Black
All colours are available in either a polished or non-slip R9 “Hammered” finish,
excepting Fossil, which is only available in a hammered finish*.
*Minimum orders of 20 full sheets per colour apply.
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White pigmented, opaque polished
type, displaying the material depth.
As part of an exciting new development, we are now able to offer decoran®
produced from Brown Beer bottle glass – in a hammered finish only – similar in
texture and appearance to cold leather.
.
Other major advances in decoran®
include bespoke Clear Galaxy, offering
greater transparency – a perfect
solution for internal partitions.
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Nature & Qualities
Colours are formed from organic and inorganic pigmentation.
The process used in production makes the glass stable and controllable.
Structuran® is available with a minimum 5 year (or project specific 10
year) guarantee.
Opacity, translucency and partial transparency can all be achieved.
High strength, anti-acid, anti-stain qualities, due to lack of porosity, provide
ideal protection against the elements and other unwelcome damage.
Sintering reduces energy consumption, using environmentally friendly bio-
gas fired ovens.
Trade Pricing Guide
Pricing is project specific, linked to the euro rate, and quotes are available on
request free of charge and with no obligation. The chart below provides a
volume pricing guide.
Project Size Net Approx. Price
100m2+ @21mm thickness structuran® plus anchors
>EUR 370/m2 *
10m2 to 50m2 structuran® decoran®
Small & complex jobs > EUR600/m2 *
>EUR 450/m2 *
* Prices are based on Jade Hammered and are exclusive of transport, cutting, anchors and edging.
Given that estimates for kitchen surface sink cut-outs etc, and for finishing and
edging work are calculated with waste sheet material very much in mind, we
strongly recommend that designs are discussed while the design is still fluid,
enabling significant cost savings to occur.
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Façades and Interiors:
Design and Specification Advice
panels offer a fresh, contemporary façade solution. Panels are
hung from top anchors onto an aluminium profile rail system, taking forces to the
structural background, while bottom anchors tie back the sheets. Joints are open
(between 8-10mm) to facilitate air ventilation behind and to prevent thermal
movement issues arising from differential temperatures. Consequently,
structuran® is only specified in closed curtain walling as a ventilated module
within a deep mullioned mixed system. The material is able to withstand external
temperatures of 60 degrees.
Above as a rain screen: Jade Hammered at Michelfeld Eye Centre, Germany
When arranging your façade, the most economic panel sizes form a division of a
full hammered sheet (maximum 2780x1260mm). As such, the more manageable
sizes, using four to six anchors, are 900mm x 1200mm, 400mm x 1200mm,
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Ventilated Rain Screen External Façades
1350mm x 1200mm and 600mm x 2700mm. While full sheets may be used with
eight anchors, this requires due care in the case of structural background
deflection. The FZP anchor allows us to use larger formats than previously.
Fischer FZP-GZ undercut anchors are fitted in our factory using trusted Fischer
setting machinery, and adhering to strict Fischer guidelines. Details are available
on request in either PDF or DWG format.
We recommend the Fischer Fixings ACT system www.fischer.co.uk as suitable
background, since the shear forces are better addressed in these profiles.
Please note that glassceramic is supplied with Fischer anchors cut in and set by
the correct torque. Fischer are not able to supply the anchors separately, and
will only quote for cleats, rails and supports. Similarly, the numbers and locations
of anchors must be calculated by SUP Engineers in Darmstadt, in accordance
with factory guidelines, as the glassceramic with anchors are guaranteed as one.
Panels are offered generally supply only ex works and are therefore fitted by
either stone or glass installers, familiar with the Fischer system. However, we
are able to recommend a list of suitable subcontractors able to offer a fitted price
including rails.
The unique structuran® material, referred to as either “sintered glass ceramic” or
“crystallized, annealed glass ceramic”, is manufactured from float glass
remnants, although it is not produced by either the float process or by continuous
casting, and therefore falls outside the remit of standards commonly used for
“glass”. It is fully compatible with all CWCT approved rain screen systems.
Worthy of note here is the fact that, while many types of natural stone have
already been incorporated in standard rain screen systems, few have been
Prior to specification, consideration must first be given to the rear surface finish
requirement, whether this surface is visible, and how the fixing is to be achieved.
Given that external façade anchor fixing can be unsightly, requiring depth of
feature, it may be more appropriate to bond the decoran® into a frame, sideways
to a steel mullion, or to bond angles to the rear side using UV or other factory
recommended glue. As a translucent barrier, the designer may wish to laminate
the decoran® to toughened glass, conferring added thickness, which may
preclude it from the application. The lamination process will add a degree of risk
and require the rear side to be polished. While this is possible, it should only be
attempted in small panel sizes.
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as a Barrier
Of equal importance is impact resistance. BS 6180 stipulates that, when used as
a barrier, “glass” must achieve either class C or class A of BS 6206, without
breaking. BS 6180 states that class A is achievable using 10mm toughened
glass. Using 21mm thick decoran®, a similar – proven – level of performance is
achieved.
Just like granite, decoran® is not usually applied as an insulated glazing panel.
Nevertheless, decoran® may still be used in a double glazing unit provided that
the unit is vapour tight, to retain any gas fill and to prevent moisture from
migrating into the unit. At the present time, a trial size 600x600mm module is
available, although further testing is required. Depending on market interest,
future experimentation may be carried out. Thermal movement is the problem in
this instance as the rearside will be at a different temperature to the frontside.
To this end, it may be our intention to create a glazing unit incorporating
decoran® that has been kite marked or certified to the current European
standard, EN 1279, made by a glazing unit manufacturer familiar with the
relevant quality system(s). Various tests identified in EN 1279 should be
repeated using the relevant decoran® product as one pane of the test unit,
enabling the manufacturer to identify the size and build-up of each unit required
for testing. EN 1279 certification will be based on a particular edge detail –
spacer, primary seal and secondary seal.
A glazing unit made with decoran® will not respond to changes in air pressure
and temperature in the same way as a conventional unit. Comparable to a fire-
resisting glazing unit with one very thick pane and one thin pane of glass, the thin
pane will invariably have to be toughened as it will be the only pane that can bow
in response to atmospheric pressure and temperature changes.
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Proposed as Insulated Glazing
Pressures generated inside the glazing unit will be much higher than in a unit
with two panes of equal-thickness.
Impact resistance to BS 6206 and EN 12600 is of paramount importance for
glazing used in critical locations, as previously explored under barrier
applications.
Given that current measuring techniques may not yet be sufficiently accurate for
the highly variable decoran® product, with its textured surface, a potential issue
regarding solar energy transmittance may arise. The relevant standard is EN
410.
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Technical Specifications
DimensionsStandard panel sizeMaximum panel size
1200 x 900 [mm], thickness 20 [mm]2780 x 1260 [mm], thickness 20 mm]
Dimensional tolerancesDimensionsThickness
±1,20 [mm]±1,00 [mm] high polish±1.20 [mm] hammered finish
Specific gravity Approx. 2.4 [g/cm³]Weight per m² with 20mm thickness
Approx. 48.00 [kg]
Bending strengthCharacteristic value5% fractile
Approx. 28 [MPa]Approx. 22 [MPa]
DIN 52112
Tearing strength attachment point{anchors attached to the rear from the firm of Keil, placement depth 13 mm}
Approx. 3.2 [KN] {average value}
Elasticity module Approx. 57 [kN/mm²] average value
HardnessAccording to MohsAccording to Vickers HV
5 guaranteed (7 achieved)5-6 [GPa]
DIN EN 101
Heat expansion 20-100ºC
7.22 [10 -6/K] DIN EN 103
Heat conductivity at 64ºC
1.04 [W/m K] at 20mm thickness
Specific heat capacity Cp
0.7 [J/g K]
Water absorption < 0.1 [Ma.-%] DIN EN 99
Frost resistance No trials with visible defects
DIN EN 202
Stain resistance Class 1 DIN EN 122
Chemical resistance Class AA DIN EN 122
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European Approvals
IFBT Tested façade integrity general approval with the FZP GZ anchor. 2006ETA applied for
Summary of Testing in the UK Completed 2009
Water absorption under vacuumFlexural strength to EN 13161
Planned UK Testing 2010
Soft body impact to BS 8200/EN 12600 Soft body impact to BS 6206 and EN 12600 in standard test frames Optical properties to EN 410 Certification to EN 1279
Project Precedent (Selective List of Completed Works)
External Facades:
UK
Land Securities, 55-69 Old Broad St. City of London. Hunter Evans Architects. Jade Hammered
World
Am Folkwang Museum, Essen. David Chipperfield Architects. Galaxy Hammered. Germany
Daimler Chrysler Aerospace, Offices MTU Ludwigsfelde. Gewers Kuehn & Kuehn. Arctis Ham’rd. Germany
Residential block. Helena-Weigel-Pltz, Berlin Marzahn, Gewers Kuehn & Kuehn, Mint Ham’rd. Germany
Health Institute Laboratory, Mannheim. Agave and Palm Polished. GermanyLenne Triangle, Offices/Residential, Potzdamer Pltz, Berlin. Petzinka Pink & Ptnr. Jade
Ham’rd. GermanySparkasse Bank, Walburgerstr. Witzenhausen, Kassel. Schubert Architect. Jade
Hammered. GermanyMuseum Abtei Liesborn, Wadesloh, Dortmund. Professor Baumewerd Architect. Jade
items. Galaxy PolishedSt Pauls Square, Liverpool. British Land. Lit reception linings/desk. RHWL Architects. Jade
PolishedManchester Academy Bar, Manchester. Lit bar fronts. Interbar. Galaxy HammeredKingsgate House, Redhill. PPG South. Vanity surfaces. Carey Jones Architects. Galaxy
PolishedTerminal 5, London Heathrow. Sony Style Retail lit flooring. AM System. Clear Jade60 St. Martins Lane, Covent Garden, London. ING Bank. Lit reception linings. Hunter